Altivar 61 Variable Speed Drives Simplified Manual

Transcription

1 Instruction Bulletin Retain for future use. Altivar 61 Variable Speed Drives Simplified Manual hp ( kw) / V hp ( kw) / V hp ( kw) / V For Use in the United States of America

2 Altivar 61 Variable Speed Drive Controllers Simplified Manual 09/ Schneider Electric All Rights Reserved

3 Altivar 61 Variable Speed Drive Controllers Simplified Manual 09/2008 Table of Contents TABLE OF CONTENTS Hazard Categories and Special Symbols Please Note Before you begin Product Support SETTING UP THE DRIVE SHORT-CIRCUIT MARKING SYSTEM APPLIED TO SCHNEIDER ELECTRIC AC DRIVES Output Interrupting Rating Input Withstand Current Rating (without line reactor or choke) Drive Containment Rating with OCPD Three phase motor 200 V to 240 V Three phase motor 380 V to 480 V Three phase motor 500 V to 690 V RECEIVING, HANDLING, AND STORAGE Mounting and Temperature Conditions Dimensions and Weights DC Bus Voltage Measurement Procedure WIRING Power Power Terminals Control Terminals CONNECTION DIAGRAMS Operation on an Isolated, Impedance Grounded (IT), or Corner Grounded Delta System ELECTROMAGNETIC COMPATIBILITY, WIRING Principle and precautions SETUP PRELIMINARY RECOMMENDATIONS Drive settings (factory configuration) Power switching via line contactor Starting DISPLAY TERMINALS Graphic Display Terminal Integrated Display Terminal Access to Menus [1.1 SIMPLY START] (SIM-) MENU Macro configuration Parameters that can be changed while the drive is running or stopped

4 Altivar 61 Variable Speed Drive Controllers Simplified Manual Table of Contents 09/2008 DETECTED FAULTS AND TROUBLESHOOTING Drive does not start, no detected fault code displayed Conditions requiring a power reset Auto-Reset Conditions (customer configured) Auto-Reset Conditions

5 Altivar 61 Variable Speed Drive Controllers Simplified Manual 09/2008 Table of Contents Hazard Categories and Special Symbols The following symbols and special messages may appear in this manual or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. A lightning bolt or ANSI man symbol in a Danger or Warning safety label on the equipment indicates an electrical hazard which, as indicated below, can or will result in personal injury if the instructions are not followed. The exclamation point symbol in a safety message in a manual indicates potential personal injury hazards. Obey all safety messages introduced by this symbol to avoid possible injury or death. Symbol Name Lightning Bolt ANSI Man Exclamation Point DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. 5

6 Altivar 61 Variable Speed Drive Controllers Simplified Manual Table of Contents 09/2008 Please Note CAUTION CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in property damage. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. 6

7 Altivar 61 Variable Speed Drive Controllers Simplified Manual 09/2008 Table of Contents Before you begin Read and understand these instructions before performing any procedure on this drive 1. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Read and understand this manual before installing or operating the Altivar 61 drives. Installation, adjustment, repair, and maintenance must be performed by qualified personnel. The user is responsible for conforming to all applicable code requirements with respect to grounding the equipment. Many parts in this drive, including printed wiring boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools. DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present. Before servicing the drive: Disconnect all power including external control power that may be present before servicing the drive. Place a DO NOT TURN ON label on the drive disconnect. Lock disconnect in the open position. WAIT 15 MINUTES for the DC bus capacitors to discharge. Then follow the DC bus voltage measurement procedure on page 24 to verify that the DC voltage is less than 42 V. The drive LEDs are not indicators of the absence of DC bus voltage. Install and close all covers before applying power or starting and stopping the drive. Failure to follow these instructions will result in death or serious injury. 1 The word drive as it is used in this manual refers to the controller portion of the adjustable speed drive as per the NEC. 7

8 Altivar 61 Variable Speed Drive Controllers Simplified Manual Table of Contents 09/2008 WARNING LOSS OF CONTROL FROM A COMMUNICATION INTERRUPTION The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and overtravel stop. Separate or redundant control paths must be provided for critical control functions. System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link. 1 Each implementation of an Altivar 61 drive must be individually and thoroughly tested for proper operation before being placed into service. Failure to follow these instructions can result in death, serious injury, or equipment damage. 1 For additional information refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems. CAUTION IMPROPER DRIVE OPERATION If, for a prolonged period of time, voltage is not applied to the drive, the performance of its electrolytic capacitors will be reduced. If it is stopped for a prolonged period, turn the drive on every two years for at least 5 hours to restore the performance of the capacitors, then check its operation. It is recommended that the drive not be connected directly to the line voltage. The voltage should be increased gradually using an adjustable AC source. Failure to follow these instructions can result in equipment damage. 8

9 Altivar 61 Variable Speed Drive Controllers Simplified Manual 09/2008 Table of Contents Product Support For more information, call, fax, or write: Schneider Electric AC Drives Product Support Group P.O. Box Raleigh, NC For support and assistance, contact the Product Support Group. The Product Support Group is staffed Monday through Friday from 8:00 am until 6:00 pm Eastern time to assist with product selection, start-up, and diagnosis of product or application problems. Emergency phone support is available 24 hours a day, 365 days a year. Toll free: Fax Line: SquareD ( ) drive.products.support@us.schneider-electric.com

10 Altivar 61 Variable Speed Drive Controllers Simplified Manual Table of Contents 09/

11 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Setting Up the Drive Setting Up the Drive b 1 Take delivery of the drive Ensure that the catalog number printed on the label is the same as that on the purchase order. Remove the drive from its packaging and ensure that it has not been damaged in transit. b 2 Check the line voltage Ensure that the line voltage is compatible with the voltage range of the drive. Steps 1 4 must be performed with the power off. b 3 Mount the drive (page 20) Mount the drive according to the instructions in this document. Install any internal and external options. b 4 Wire the drive (page 25). Connect the motor, ensuring that its connections correspond to the voltage. With power off, connect the line supply. Connect the control wiring. Connect the speed reference. b 5 Energize drive with no inputs active. Removing the control terminal card ensures no active inputs. See page 30 for control terminal card removal procedure. b 6 Select the language (page 42), if the drive is equipped with a graphic display terminal. NOTE: Ensure that the wiring of the drive is compatible with its configuration. b 7 Configure the menu [SIMPLY START] (SIM-) (page 44) 2-wire or 3-wire control Macro configuration Motor parameters Optimize performance To optimize performance: Refer to the auto-tuning section on page 53. Motor thermal current Acceleration and deceleration ramps Speed variation range b 8 Start. 11

12 Altivar 61 Variable Speed Drives Simplified Manual Short-Circuit Marking System Applied to Schneider Electric AC Drives 09/2008 Short-Circuit Marking System Applied to Schneider Electric AC Drives Output Interrupting Rating Altivar drives have a prospective short-circuit rating that is based on three performance attributes that affect all drives. The performance attributes are characterized by three rating parameters described below and listed in Tables 1 4 on pages The overall maximum rating of the drive is the lowest of the three ratings. Higher ratings can be attained for Altivar drives. Contact Schneider Electric for tested combinations of overcurrent protective devices (OCPD), line reactors, and enclosures or refer to the Altivar 61and 71 Supplementary Short Circuit Protection Information bulletin shipped with the drive. The maximum prospective input short-circuit current at which the drive is capable of interrupting a short-circuit at its motor output terminals. The output interrupting rating conforms to the existing short-circuit requirements of UL508C 3rd edition with revisions effective February 15, Input Withstand Current Rating (without line reactor or choke) The maximum prospective input short-circuit current at the drive input terminals with which the drive was designed to operate. The input withstand current rating is an important parameter in determining the maximum thermal and electrical operating limits for the drive. Exceeding the maximum prospective input short-circuit current rating may cause overheating with reduction of drive life expectancy or damage to the drive. CAUTION DRIVE OVERHEATING Ensure the prospective input short-circuit current does not exceed the input withstand current rating. Failure to follow these instructions can result in equipment damage. 12

13 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Short-Circuit Marking System Applied to Schneider Electric AC Drives Drive Containment Rating with OCPD The maximum prospective input short-circuit current at the drive input terminals with the marked OCPD present at which an internal component breakdown in the drive will not create a shock, flame, fire or expulsion hazard outside the marked enclosure structure. This rating applies to drives with a listed enclosure rating or to drives that have a listed enclosure rating with the addition of conduit box. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Only use the overcurrent protective device marked on the drive or in the manual. Do not operate the drive on an input mains line with a prospective input short circuit current greater than the Drive Containment Rating. Ensure that the drive has a listed enclosure rating or uses the conduit kit to achieve an enclosure rating. Failure to follow these instructions will result in death or serious injury. Use of the drive with different prospective short-circuit currents may be possible. Contact Schneider Electric for tested combinations of OCPD, line reactors, drives and enclosures or refer to the Altivar 61 and 71 Supplementary Short Circuit Protection Information bulletin shipped with the drive. 13

14 Altivar 61 Variable Speed Drives Simplified Manual Short-Circuit Marking System Applied to Schneider Electric AC Drives 09/2008 Three phase motor 200 V to 240 V For drives with an input line voltage of 200 V to 240 V, a Class J time delay or non-time delay fuse is required. Table 1 on page 14 shows the maximum available short-circuit current value for each of the rating parameters. Table 1: 200 V to 240 V 50/60 Hz Single Phase Supply Voltage Altivar 61 Drive Power Indicated on Plate 1 Part Number 2 Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw hp ka ka ka A ATV61H075M ATV61HU15M ATV61HU22M ATV61HU30M ATV61HU40M ATV61HU55M ATV61HU75M These power ratings and currents are given for an ambient temperature of 50 C (122 F) at the factory-set switching frequency, used in continuous operation. 2 These part numbers are also available without a graphic terminal display by adding a Z to the end of the part number, for example, ATV61H075M3Z. 3 A line choke must be used. Refer to the drives catalog for more information. Table 2: 200 V to 240 V 50/60 Hz Three Phase Supply Voltage Altivar 61 Drive Power Indicated on Plate 1 Part Number 2 Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw hp ka ka ka A ATV61H075M ATV61HU15M ATV61HU22M ATV61HU30M ATV61HU40M ATV61HU55M ATV61HU75M

15 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Short-Circuit Marking System Applied to Schneider Electric AC Drives Table 2: 200 V to 240 V 50/60 Hz Three Phase Supply Voltage (continued) Altivar 61 Drive Power Indicated on Plate 1 Part Number 2 Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw hp ka ka ka A ATV61HD11M3X ATV61HD15M3X ATV61HD18M3X ATV61HD22M3X ATV61HD30M3X ATV61HD37M3X ATV61HD45M3X These power ratings and currents are given for an ambient temperature of 50 C (122 F) at the factory-set switching frequency, used in continuous operation. These part numbers are also available without a graphic terminal display by adding a Z to the end of the part number, for example, ATV61H075M3Z. Three phase motor 380 V to 480 V For drives with an input line voltage of 380 V to 480 V, a Class J time delay or non-time delay fuse is required. Table 3 shows the fuse size required and available short circuit current rating associated with each drive. Table 3: 380 V to 480 V, 50/60 Hz Three Phase Supply Voltage Altivar 61 Drive Power Indicated on Plate 1 Part Number 2 Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw hp ka ka ka A ATV61H075N ATV61HU15N ATV61HU22N ATV61HU30N ATV61HU40N ATV61HU55N ATV61HU75N ATV61HD11N

16 Altivar 61 Variable Speed Drives Simplified Manual Short-Circuit Marking System Applied to Schneider Electric AC Drives 09/2008 Table 3: 380 V to 480 V, 50/60 Hz Three Phase Supply Voltage (continued) Altivar 61 Drive Power Indicated on Plate 1 Part Number 2 Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw hp ka ka ka A ATV61HD15N ATV61HD18N ATV61HD22N ATV61HD30N ATV61HD37N ATV61HD45N ATV61HD55N ATV61HD75N These power ratings and currents are given for an ambient temperature of 50 C (122 F) at the factory-set switching frequency, used in continuous operation. These part numbers are also available without a graphic terminal display by adding a Z to the end of the part number, for example, ATV61H075M3Z. Three phase motor 500 V to 690 V For drives with an input line voltage of 500 V to 690 V, a Class J time delay or non-time delay fuse is required. Table 4 shows the fuse size required and available short circuit current rating associated with each drive. Table 4: 500 V to 690 V, 50/60 Hz Three Phase Supply Voltage Power Indicated on Plate 1 Part Number Altivar 61 Drive Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw (500 V) hp (600 V) kw (690 V) ka ka ka A ATV61HU30Y ATV61HU40Y ATV61HU55Y ATV61HU75Y ATV61HD11Y

17 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Short-Circuit Marking System Applied to Schneider Electric AC Drives Table 4: 500 V to 690 V, 50/60 Hz Three Phase Supply Voltage (continued) Power Indicated on Plate 1 Part Number Altivar 61 Drive Output Interrupting Rating Input Withstand Current Drive Containment Rating Max. Fuse Size kw (500 V) hp (600 V) kw (690 V) ka ka ka A ATV61HD15Y ATV61HD18Y ATV61HD22Y ATV61HD30Y ATV61HD37Y ATV61HD45Y ATV61HD55Y ATV61HD75Y ATV61HD90Y These power ratings and currents are given for an ambient temperature of 50 C (122 F) at the factory-set switching frequency, used in continuous operation. 17

18 Altivar 61 Variable Speed Drives Simplified Manual Receiving, Handling, and Storage 09/2008 Receiving, Handling, and Storage Handling and storage To help protect the drive prior to installation, handle and store the device in its packaging. Ensure that the ambient conditions are acceptable. Refer to Dimensions and Weights on page 22. WARNING DAMAGED PACKAGING If the packaging appears damaged, it can be dangerous to open it or handle it. Handle with care. Failure to follow these instructions can result in death or serious injury. WARNING DAMAGED DRIVE EQUIPMENT Do not operate or install any drive or drive accessory that appears damaged. Failure to follow these instructions can result in death or serious injury. Handling during installation 45 max. Altivar 61 drives up to 20 hp (see Table 1and Table 2 on page) and 25 hp (table & page) can be removed from their packaging and installed without a handling device. A hoist must be used for higher ratings and for ATV61H Y drives; for this reason the controllers are fitted with handling holes. Attach a spreader bar to the top handling holes on the drive. 18

19 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Receiving, Handling, and Storage WARNING RISK OF TOPPLING Do not stand the drive upright. Keep the drive on the pallet until it is installed. Failure to follow these instructions can result in death or serious injury. Before You Begin You must observe the following precautions. DANGER UNINTENDED EQUIPMENT OPERATION Before turning on and configuring the Altivar 61 drive, ensure that the PWR (POWER REMOVAL) input is deactivated (at state 0) in order to help prevent unintended operation. Before turning the controller on or upon exiting the configuration menus, ensure that the inputs assigned to the run command are deactivated (at state 0) since they can cause the motor to start immediately. Refer to the characteristics and functions table in the Control Terminals section on page 30 for more information about the Power Removal Input. Failure to follow these instructions will result in death or serious injury. 19

20 Altivar 61 Variable Speed Drives Simplified Manual Receiving, Handling, and Storage 09/2008 NOTE: The Power Removal function takes priority over any run command. For use as an emergency stop, this function requires the use of connection diagrams conforming to category 3 of standard EN and safety integrity level 2 according to IEC/EN Consult the ATV61 Installation Manual on the CD-ROM supplied with the drive. Mounting and Temperature Conditions CAUTION INCOMPATIBLE LINE VOLTAGE Before turning on and configuring the drive, ensure that the line voltage is compatible with the supply voltage range shown on the drive nameplate. The drive may be damaged if the line voltage is not compatible. Failure to follow these instructions can result in equipment damage. 100 mm 3.94 in. 100 mm 3.94 in. Install the drive vertically, ±10. Do not place it close to heating elements. Leave a minimum of 10 mm (0.39 in.) free space in front of the drive to ensure that the air required for cooling purposes can circulate from the bottom to the top of the unit. Where IP20 protection is adequate, we recommend that you remove the cover on top of the drive, as shown below in diagrams A and B. Removing the top cover ATV61H 075M3 to D15M3X 1 and ATV61H D18M3X to D45M3X 1, ATV61H D22N4 to D75N4 2, ATV61H 075N4 to D18N4 2 and ATV61H U30Y to D90Y 3 A B 1 For drive part numbers, see Table 2 on page For drive part numbers, see Table 3 on page For drive part numbers, seetable 4 on page

21 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Receiving, Handling, and Storage 3 types of mounting are possible: Type A mounting: Free space 50 mm ( 1.97 in.) on each side, with cover in place. 50 mm 1.97 in. 50 mm 1.97 in. Type B mounting: Drives mounted side by side, with the cover removed (the degree of protection becomes IP20). Type C mounting: Free space 50 mm ( 1.97 in.) on each side, with cover removed (the degree of protection becomes IP20). 50 mm 1.97 in. 50 mm 1.97 in. With these types of mounting, the drive can be used without derating up to an ambient temperature of 50 C (122 F), with the factory-set switching frequency. For other temperatures and other switching frequencies, consult the Installation Manual on the CD-ROM supplied with the drive. 21

22 Altivar 61 Variable Speed Drives Simplified Manual Receiving, Handling, and Storage 09/2008 Dimensions and Weights Refer to the Dimensions table on page 23. With graphic display terminal No option card 1 option card (1) (1) For the addition of I/O extension cards, communication cards, or the Controller Inside programmable card. 2 option cards (1) Without graphic display terminal No option card 1 option card (1) b c c1 For a drive without a graphic display terminal, dimensions c, c1 and c2 are reduced by 26 mm (1.01 in.). The other dimensions are unchanged. 2 option cards (1) 4 x H h (1) For the addition of I/O extension cards, communication cards, or the Controller Inside programmable card. c2 = G = a 22

23 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Receiving, Handling, and Storage Table 5: Dimensions ATV61H Dimensions, mm (in.) Weight a b c c1 c2 G H h Ø kg (lb) Screws 075M3, U15M3, 075N4, U15N4, U22N4 130 (5.12) 230 (9.05) 175 (6.89) 198 (7.80) 221 (8.70) (4.47) 220 (8.66) 5 (0.20) 5 (0.20) M4 3 (6.61) U22M3, U30M3, U40M3, U30N4, U40N4 155 (6.10) 260 (10.23) 187 (7.36) 210 (8.27) 233 (9.17) 138 (5.43) 249 (9.80) 4 (0.16) 5 (0.20) M4 4 (8.82) U55M3, U55N4, U75N4 175 (6.89) 295 (11.61) 187 (7.36) 210 (8.27) 233 (9.17) 158 (6.22) 283 (11.14) 6 (0.24) 5 (0.20) M4 5.5 (12.13) U75M3, D11N4 210 (8.27) 295 (11.61) 213 (8.39) 236 (9.29) 259 (10.20) 190 (7.48) 283 (11.14) 6 (0.24) 6 (0.24) M5 7 (15.43) D11M3X, D15M3X, D15N4, D18N4 230 (9.05) 400 (15.75) 213 (8.39) 236 (9.29) 259 (10.20) 210 (8.26) 386 (15.20) 8 (0.31) 6 (0.24) M5 9 (19.84) D18M3X, D22M3X, D22N4, U30Y to D30Y 240 (9.45) 420 (16.54) 236 (9.29) 259 (10.20) 282 (11.10) 206 (8.11) 403 (15.87) 11 (0.45) 6 (0.24) M5 30 (66.14) D30N4, D37N4, 240 (9.45) 550 (21.65) 266 (10.47) 289 (11.38) 312 (12.28) 206 (8.11) (20.93) 11 (0.45) 6 (0.24) M5 37 (81.57) D30M3X, D37M3X, D45M3X 320 (12.60) 550 (21.65) 266 (10.47) 289 (11.38) 312 (12.28) 280 (11.02) 524 (20.93) 20 (0.79) 9 (0.35) M8 37 (81.57) D45N4, D55N4, D75N4 D37Y to D90Y 320 (12.60) 630 (24.80) 290 (11.42) 313 (12.32) 334 (13.15) 280 (11.02) (23.80) 15 (0.59) 9 (0.35) M8 45 (99.21) 23

24 Altivar 61 Variable Speed Drives Simplified Manual Receiving, Handling, and Storage 09/2008 DC Bus Voltage Measurement Procedure Measuring the DC bus voltage Before working on the drive, turn it off and wait 15 minutes to allow the DC bus to discharge. Then measure the DC bus voltage. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Read and understand the instructions on page 7 before performing this procedure. Failure to follow these instructions will result in death or serious injury. The DC bus voltage can exceed 1,000 V c. Use a properly rated voltage-sensing device when performing this procedure. To measure the DC bus voltage: 1. Disconnect the drive power supply. 2. Wait 15 minutes to allow the DC bus to discharge. 3. Measure the voltage of the DC bus between the PO and PC/ terminals to ensure that the voltage is less than 42 V c. 4. If the DC bus capacitors do not discharge completely, contact your local Schneider Electric representative. Do not repair or operate the drive. ATV61H 075M3 to D15M3X 1 ATV61H D18M3X to D45M3X 1 and ATV61H 075N4 to D18N4 2 ATV61H D22N4 to D75N4 2, and ATV61H U30Y to D90Y 3 Red LED indicating that the DC bus is turned on. The drive LEDs are not indicators of the absence of DC bus voltage. 1 For drive part numbers, see Table 2 on page For drive part numbers, see Table 3 on page For drive part numbers, see Table 4 on page

25 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Wiring Wiring Power Ground the drive to local and national code requirements. A minimum wire size of mm² (6 AWG) may be required to meet standards limiting leakage current. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Ground equipment using the provided ground connecting point as shown in the figure below. The drive panel must be properly grounded before power is applied. Failure to follow these instructions will result in death or serious injury. YES NO Drive Drive Drive Drive Drive Drive Drive Drive Drive Ensure that the resistance of the ground is 1 Ω or less. If grounding several drives you must connect each one directly, as shown in the figure above. Do not loop the ground cables or connect them in series 25

26 Altivar 61 Variable Speed Drives Simplified Manual Wiring 09/2008 WARNING IMPROPER WIRING PRACTICES The ATV61 controller will be damaged if input line voltage is applied to the output terminals (U/T1,V/T2,W/T3). Check the power connections before energizing the ATV61 drive. If replacing another drive, verify that all wiring connections to the ATV61 controller comply with all wiring instructions in this manual. Failure to follow these instructions can result in death, serious injury, or equipment damage. Where local and national codes require upstream protection by means of a residual current device, use a Type A device for singlephase drives and a Type B device for three-phase drives as defined in the IEC Choose a suitable model integrating: Harmonic Frequency (HF) current filtering A time delay that helps prevent tripping caused by the load from stray capacitance on power-up. The time delay is not possible for 30 ma devices; in this case, choose devices with immunity against nuisance tripping. If the installation includes several drives, provide one residual current device per drive. 26

27 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Wiring WARNING INADEQUATE OVERCURRENT PROTECTION Overcurrent protective devices must be properly coordinated. The Canadian Electrical Code and the National Electrical Code require branch circuit protection. Use the over current protective device recommended on the drive nameplate or in document _ to achieve published short-circuit current ratings. Do not connect the drive to a power feeder whose short-circuit capacity exceeds the controller short-circuit current rating listed on the controller nameplate or in document _. Failure to follow these instructions can result in death, serious injury, or equipment damage. CAUTION IMPROPER USE OF A BRAKING RESISTOR Wire the thermal protection contact on the resistor so that the drive power supply is disconnected immediately in the event of a detected fault (refer to the manual supplied with the resistor). Failure to follow these instructions can result in equipment damage. 27

28 Altivar 61 Variable Speed Drives Simplified Manual Wiring 09/2008 Power Terminals Access to the power terminals ATV61 H075M3 to HD15M3X 1 and ATV61 H075N4 to HD18N4 2 Unlock the power-section access flap, and remove it as shown below. ATV61 HD18M3X to HD45M3X 1, ATV61 HD22N4 to HD75N4 2, and ATV61H U30Y to HD90Y 3 To access the power terminals, remove the front panel as shown below. 1 For drive part numbers, see Table 2 on page For drive part numbers, see Table 3 on page For drive part numbers, see Table 4 on page 16. Functions of power terminals Terminals t R/L1 S/L2 T/L3 PO PA/+ PB PC/ U/T1 V/T2 W/T3 Function Protective ground connection terminal Power section line supply DC bus +polarity Output to braking resistor (+polarity) Output to braking resistor DC bus polarity Outputs to the motor NOTE: Remove the link between PO and PA/+ only if a DC choke has been added. The PO and PA/+ terminal screws must always be fully tightened, since a high current flows through the common link. Refer to the table on page 29 for tightening torque. 28

29 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Wiring Characteristics of power terminals Table 6: Characteristics of power terminals ATV61H 075M3, U15M3, U22M3, U30M3, U40M3,075N4, U15N4, U22N4, U30N4, U40N4, Maximum wire size Tightening torque mm² AWG kcmils N m (lb-in) (12.3) U55M3, U55N4, U75N (26.5) U73M3, D11N (26.5) D11M3X, D15M3X, D15N4, D18N (47.7) D18M3X, D22M3X, D22N4, D30N4, D37N4, U30Y to D30Y /0 12 (106.2) D30M3X, D37M3X, D45M3X, D45N4, D55N4, D75N4, (360) D37Y to D90Y 1 1 For drive part numbers, see Table 4 on pages16 and

30 Altivar 61 Variable Speed Drives Simplified Manual Wiring 09/2008 Control Terminals Access to the control terminals To access the control terminals, open the cover on the front panel of the control section. 2. To make it easier to wire the drive control section, remove the control terminal card by loosening the screw until the spring is fully extended. 3. Remove the card by sliding it downwards. NOTE: For control wiring the maximum wire size is 2.5 mm² (14 AWG). The maximum tightening torque is 0.6 N m (5.3 lb-in). DANGER UNINTENDED EQUIPMENT OPERATION The accidental grounding of logic inputs configured for Sink Logic can result in unintended activation of drive functions. Protect the signal conductors against damage that could result in unintentional conductor grounding. Follow NFPA 79 and EN guidelines for proper control circuit grounding practices. Failure to follow these instructions will result in death or serious injury. CAUTION IMPROPERLY SECURED TERMINAL CARD When replacing the control terminal card, it is essential to fully tighten the captive screw. Torque the captive screw to 1.1 to 1.7 N m (9.7 to 15 lb-in). Failure to follow these instructions can result in equipment damage. 30

31 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Wiring Table 7: Characteristics and functions of the control terminals Terminals Function R1A R1B R1C R2A R2C 1 relay logic output, one N.C. contact and one N.O. contact with common point (R1A to R1C is N.O.; R1B to R1C is N.C.) 1 relay logic output one N.O. contact V c power supply for reference potentiometer 1 to 10 kω AI1+ AI1 Electrical characteristics Minimum switching capacity: 3 ma for 24 V c Maximum switching capacity: on resistive load (cos ϕ = 1): 5 A for 250 V a or 30 V V c on inductive load (cos ϕ = 0.4 and L/R = 7 ms): 2 A for 250 V a or 30 V c Max. response time: 7 ms ±0.5 ms Electrical service life: 100,000 operations +10 V c (10.5 V ±0.5 V) 10 ma max. Differential analog input AI1 10 to +10 V c (max. safe voltage 24 V) Reaction time: 2 ms ±0.5 ms, 11-bit resolution + 1 sign bit Accuracy ±0.6% for Δθ = 60 C (140 F), linearity ±0.15% of max. value COM Analog I/O common 0 V AI2 Depending on the software configuration: Analog input 0 to +10 V c (max. safe voltage 24 V), impedance 30 kω Analog voltage or current input Analog input X Y ma, X and Y programmable from 0 to 20 ma, impedance 250 Ω Reaction time: 2 ms ±0.5 ms 11-bit resolution, accuracy ±0.6% for Δθ = 60 C (140 F), linearity ±0.15% of max. value COM Analog I/O common 0 V AO1 P24 0V LI1 LI2 LI3 LI4 LI5 LI6 Depending on the software configuration: Analog voltage or current output or logic output Input for external +24 V c control power supply Logic input common and 0 V of external P24 power supply Analog output 0 to +10 V c, min. load impedance 50 kω Analog output X Y ma, X and Y can be programmed from 0 to 20 ma, max. load impedance 500 Ω 10-bit resolution, reaction time: 2 ms ±0.5 ms Accuracy ±1% for Δθ = 60 C (140 F), linearity ±0.2% of max. value Logic output: 0 or 10 V, 0 to 20 ma +24 V c (min. 19 V, max. 30 V) Power 30 W 0 V Programmable logic inputs +24 V c (max. 30 V) Impedance 3.5 kω Reaction time: 2ms ±0.5 ms Depending on the position of the SW2 switch: LI (Programmable logic input) or PTC (Input for PTC probes) NOTE: Δθ = temperature change SW1 Switch State 0 State 1 Source (factory setting) < 5 V c > 11 V c Sink Int or Sink Ext SW2 = LI (factory setting): Same characteristics as logic inputs LI1 to LI5 SW2 = PTC: Trip threshold 3 kω, reset threshold 1.8 kω Short-circuit detection threshold < 50 Ω > 16 V c < 10 V c 31

32 Altivar 61 Variable Speed Drives Simplified Manual Wiring 09/2008 Table 7: Characteristics and functions of the control terminals (continued) Terminals Function Electrical characteristics +24 Logic input power supply SW1 switch in Source or Sink Int position: Internal +24 V c power supply (min. 21 V, max. 27 V), protected against short-circuits and overloads 200 ma max. SW1 switch in Sink Ext position: Input for external +24 V c power supply for the logic inputs PWR Power Removal input. 24 V c (max. 30 V) Impedance 1.5 kω State 0 if < 2 V, state 1 if > 17 V Reaction time: 10 ms When PWR is not connected to 24 V, the motor cannot be started (compliance with functional safety standard EN and IEC/EN 61508). NOTE: Δθ = temperature change Arrangement of the control terminals SW2 SW1 Logic input switch Source Factory Sink Ext setting: Int Source R1A R1B R1C R2A R2C +10 AI1+ AI1- COM AI2 COM AO1 LI6 input switch P24 0V LI1 LI2 LI3 LI4 LI5 LI6 +24 PWR RJ45 PTC LI RJ45 connector Factory setting: LI Maximum wire size: 2.5 mm² (14 AWG) Max. tightening torque: 0.6 N m (5.3 lb-in) Note: The ATV61 controller is supplied with links between the PWR and +24 terminals and the AI1 and COM terminals. 32

33 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Connection diagrams Connection diagrams bh (1) ATV61HO75M3 to ATV61HU75M3 only Single-phase supply R / L1 S / L2 ATV61 3-phase supply (2) (1) R / L1 S / L2 T / L3 U / T1 V / T2 W / T3 M R1A (4) R1C (3) R1B P0 PA / + R2A PB R2C PC / - Braking resistor, if used P24 0 V LI1 +10 AI1 + LI2 Reference potentiometer LI3 AI1 - COM LI4 AI2 LI5 0 to +10 V or X Y ma COM LI6 +24 AO1 PWR Line reactor, if used (required in single phase operation for ATV61H U40M3 to U75M3 drives). Recommended for 575 V installations. For recommended fuses, refer to Tables 1 4 on pages14 16, the drive nameplate, or the Altivar 61 and 71 Supplementary Short Circuit Protection Information bulletin shipped with the drive. R1 relay contacts, for remote signaling of drive status. Installation of a load reactor or motor protecting filter is recommended for all 575 V installations. 3 c NOTE: To operate the drive on a single phase supply, you must inhibit the input phase loss detection. If the input phase loss detection is set to its factory configuration, the drive will display a PHF code until the input phase loss is inhibited. For possible drives, see Table 1 on page 14. Install interference suppressors on all inductive circuits near the drive or coupled to the same circuit (such as relays, contactors, and solenoid valves). Use shielded cable for PWR input connections. See page 38 for factory configurations for logic inputs, analog inputs, relays and analog inputs. 33

34 Altivar 61 Variable Speed Drives Simplified Manual Connection diagrams 09/2008 Operation on an Isolated, Impedance Grounded (IT), or Corner Grounded Delta System Isolated or impedance grounded (IT) neutral system: Use a permanent insulation monitor compatible with non-linear loads, such as a Merlin Gerin Type XM200 or equivalent. Altivar 61 drives feature built-in common mode RFI (EMC) filters. When any ATV61 drive is operating on an isolated or impedance grounded electrical distribution system, the filters must be isolated (disconnected). NOTE: The ATV61D22N4 has two jumpers for filter disconnection. CAUTION DRIVE DAMAGE Do not exceed 4 khz switching frequency on ATV61H 075N4(Z), U15N4(Z), U22N4(Z), U30N4(Z), U40N4(Z drives if the filters are disconnected. Refer to the programming manual on the CD-ROM supplied with the drive to adjust parameter SFr. Failure to follow these instructions can result in equipment damage. Disconnecting the filter For ATV61HO75M3 ATV61HD45M3X 1, ATV61HO75N4 ATV61HD75N4 2, and ATV61HU3OY ATV61HD30Y 3 ATV61pD22N4 Normal (filter connected) IT system (filter disconnected) 1 For ATV61 part numbers, see Tables 1 and 2 on pages 14 and For ATV61 part numbers, see Table 3 on pages15 and 16. For ATV61 part numbers, see Table4 on pages 16 and

35 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Connection diagrams For ATV61HD37Y, ATV61HD45Y, ATV61HD55Y, ATV61HD75Y, and ATV61HD90Y Normal (filter connected) IT system (filter disconnected) WARNING RISK OF ELECTRIC SHOCK ATV61 Y drives must not be connected to a corner grounded system. Failure to follow these instructions can result in death, serious injury, or equipment damage. Corner grounded delta systems: The ATV61HU30Y ATV61HD90Y drives 1 must never be connected on a corner grounded delta electrical distribution system. When any other drive referenced in this manual is connected to a corner grounded delta electrical distribution system the filters must be isolated (disconnected) as shown in the diagram above. 1 For ATV61 part numbers, see Table 4 on pages16 and

36 Altivar 61 Variable Speed Drives Simplified Manual Electromagnetic Compatibility, Wiring 09/2008 Electromagnetic Compatibility, Wiring Principle and precautions Important: The high frequency equipotential ground connection between the drive, motor, and cable shielding does not eliminate the need to connect the ground (PE) conductors (green-yellow) to the appropriate terminals on each unit. To help accomplish this, the user must follow the following points. Grounds between the drive, motor, and cable shielding must have high-frequency equipotentiality. When using shielded cable for the motor, use a 4-conductor cable so that one wire will be the ground connection between the motor and the drive. Size of the ground conductor must be selected in compliance with local and national codes. The shield can then be grounded at both ends. Metal ducting or conduit can be used for part or all of the shielding length, provided there is no break in continuity. When using shielded cable for the Dynamic Brake (DB) resistors, use a 3-conductor cable so that one wire will be the ground connection between the DB resistor assembly and the drive. Size of the ground conductor must be selected in compliance with local and national codes. The shield can then be grounded at both ends. Metal ducting or conduit can be used for part or all of the shielding length, provided there is no break in continuity. When using shielded cable for control signals, if the cable is connecting equipment that is close together and the grounds are bonded together, then both ends of the shield can be grounded. If the cable is connected to equipment that may have a different ground potential, then ground the shield at one end only to prevent large currents from flowing in the shield. The shield on the ungrounded end may be tied to ground with a capacitor (for example: 10 nf, 100V or higher) in order to provide a path for the higher frequency noise. Keep the control circuits away from the power circuits. For control and speed reference circuits, use of shielded twisted cables with a pitch of between 25 and 50 mm (0.98 and 1.97 in.) is recommended. Ensure maximum separation between the power supply cable (line supply) and the motor cable and also ensure maximum separation between the control cables and any power cables. 36

37 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Electromagnetic Compatibility, Wiring The motor cables must be at least 0.5 m (20 in.) long. Do not use surge arresters or power factor correction capacitors on the variable speed drive output. If using an additional input filter, refer to the Installation Guide for more information. For installation of the EMC plate provided with the drive and instructions for meeting EN55011 Class A directive, refer to the Installation Guide. 37

38 Altivar 61 Variable Speed Drives Simplified Manual Setup Preliminary Recommendations 09/2008 Setup Preliminary Recommendations Drive settings (factory configuration) The Altivar 61 drive is factory-set for the following operating conditions: : Table 8: Factory configurations Macro-configuration Motor frequency Motor control type Pumps/fans 50 Hz Energy-saving variable torque applications Normal stop mode on deceleration ramp Stop mode Freewheel, in the event of a detected fault Linear, acceleration, and 3 s deceleration ramps Low speed 0 Hz High speed 50 Hz Motor thermal current Rated drive current Standstill injection braking current 0.7 x rated drive current, for 0.5 s Automatic starts No automatic starts after a detected fault is cleared Switching frequency 2.5 khz to 12 khz depending on drive rating Logic inputs Analog inputs Relay R1 Relay R2 Analog output AO1 LI1: forward (1 operating direction), 2-wire control type is transition. See Starting on page 39. LI2: inactive (not assigned) LI3: switching of 2 nd speed reference. If LI3 = 0 the speed reference AI1 is active. If LI3 = 1 the speed reference AI2 is active. LI4: fault reset LI5, LI6: inactive (not assigned) AI1: 1 st speed reference 0 to 10 V AI2: 2 nd speed reference 0 to 20 ma NOTE: For 4 20 ma, go to Menu [1.5 Input/Output CFG], then to [AI2 configuration] and change [AI2 min. value] from 0 to 4. R1C to R1A contact opens and R1C to R1B contact closes in the event of a detected fault or when the drive is powered off. R2A to R2C contact closes when the drive is running. 0 to 20 ma, motor frequency For programming instructions, refer to the ATV61 programming manual on the CD-ROM included with the drive. 38

39 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Setup Preliminary Recommendations Power switching via line contactor CAUTION EXCESSIVE LINE CONTACTOR SWITCHING Avoid operating the contactor frequently to avoid premature aging of the filter capacitors. Do not have cycle times less than 60 s. Failure to follow these instructions can result in equipment damage. Starting Important: The factory setting for the programming parameter [2-wire type] is set to [Transition], when input line power is applied nst may display as the drive state and the controller will not start. This could indicate that a run command was present before the input line power was applied and a transition or change of state must be made to this command before the drive will start. If it is desired that the drive starts when the input line power is applied without a transition of the run command, make the following change to the program configuration. Go to the menu [1.5 Inputs/Outputs CFG] and change parameter [2-wire type] from [Transition] to [Level]. When the change is made, the drive can begin running immediately on application of the input line power if a run command is present. For more information, see page 42. Test on a low-power motor or without a motor, using motors in parallel Consult the Programming Manual on the CD-ROM supplied with the drive. 39

40 Altivar 61 Variable Speed Drives Simplified Manual Display Terminals 09/2008 Display Terminals Graphic Display Terminal The graphic display terminal can be disconnected and connected remotely (on the door of an enclosure, for example) using the cables and accessories available as options. 1 Graphic display 2 Function keys F1, F2, F3, F4 3 STOP/RESET button 7 ESC key: Cancels a value, a parameter or a menu to return to the previous selection 4 RUN button 6 Button for reversing the rotation direction of the motor 5 Navigation button: Press (ENT): To save the current value To enter the selected menu or parameter Turn CW/CCW: To increase or decrease a value To go to the next or previous line To increase or decrease the reference if control via the graphic display terminal is activated NOTE: Buttons 3, 4, 5, and 6 can be used to control the drive directly, if control via the graphic display terminal is activated. 40

41 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Display Terminals Drive state codes Table 9: Drive state codes ACC Acceleration CLI Current limiting CTL Controlled stop on input phase loss DCB DC injection braking in progress DEC Deceleration FLU Motor fluxing in progress FRF Drive at fallback speed FST Fast stop NLP No line power (no line supply on L1, L2, L3) NST Freewheel stop OBR Auto-adapted deceleration PRA Power Removal function active (drive locked) RDY Drive ready RUN Drive running SOC Controlled output cut in progress TUN Auto-tuning in progress USA Undervoltage alarm The first time the drive is powered on, the user is automatically guided through the menus as far as [1. DRIVE MENU]. The parameters in the [1.1 SIMPLY START] submenu must be configured before the motor is started up. To optimize performance, perform an auto-tune (see page page 50). Only the [1.1 SIMPLY START] menu is described in this document. For more information about the content of the other menus, consult the Programming Manual and the CD-ROM supplied with the drive. 41

42 Altivar 61 Variable Speed Drives Simplified Manual Display Terminals 09/2008 ATV61HU22N4 2.2kW/3HP 380/480V Config. n 1 Displayed for 3 seconds following power-up 3 seconds English Français Deutsch Español Italiano 5 LANGUAGE Switches to [5 LANGUAGE] menu automatically. Select the language and press ENT. Chinese RDY Term +0.00Hz REM 2 ACCESS LEVEL Basic Standard Advanced Expert Switches to [2 ACCESS LEVEL] menu (consult the Programming Manual on the CD-ROM supplied with the drive) Select the access level and press ENT. RDY Term +0.00Hz REM 1 DRIVE MENU 1.1 SIMPLY START 1.2. MONITORING 1.3. SETTINGS 1.4. MOTOR CONTROL 1.5. INPUTS / OUTPUTS CFG Code << >> T/K Switches to [1 DRIVE MENU] (consult the Programming Manual on the CD-ROM supplied with the drive) ESC RDY Term +0.00Hz REM MAIN MENU 1 DRIVE MENU 2 ACCESS LEVEL 3 OPEN / SAVE AS 4 PASSWORD 5 LANGUAGE Code T/K Press ESC to return to [MAIN MENU] 42

43 Altivar 61 Variable Speed Drives Simplified Manual 09/2008 Display Terminals Integrated Display Terminal The integrated display terminal with a 7-segment 4-digit display is an optional feature for the low-power ATV61 drives. The graphic display terminal described on page 40 is supplied as standard. Returns to the previous menu or parameter, or increases the displayed value Goes to the next menu or parameter, or decreases the displayed value Exits a menu or parameter, or cancels the displayed value to return to the previous value in the memory Enters a menu or parameter, or saves the displayed parameter or value Pressing or does not store the choices. Press and hold down (>2 s) or to scroll through the data quickly. Press ENT to save and store the selection. The display flashes once a value is stored. A normal display has no detected fault present and no startup: 43.0: Display of the parameter selected in the SUP menu (default selection: motor frequency) CLI: Current limit CtL: Controlled stop on input phase loss dcb: DC injection braking in progress FLU: Motor fluxing in progress FrF: Drive at fallback speed FSt: Fast stop nlp: No line power (no line supply on L1, L2, L3) nst: Freewheel stop. Obr: Auto-adapted deceleration PrA: Power Removal function active (drive locked) rdy: Drive ready run: Drive running SOC: Controlled output cut in progress tun: Auto-tuning in progress USA: Undervoltage alarm The display flashes continuously to indicate the presence of a detected fault. 43